KRAL Volumeter - Turbine Fuel and Water Injection Measurement
Fuel Consumption Measurement for Turbines Accurate, reliable and leakage-free fuel consumption measurement, is now possible. Fuel Cost Reduction Power plant operators monitor any measurements that reduce the operating costs. They would also like to prove the turbine specifications are being met. High fuel costs make this an economic necessity. Measurement with tank level gauges or billing from the fuel supplier are influenced by temperature and fuel type variations. A practical direct measurement of fuel consumption is required. The extremely accurate KRAL Volumeters are installed directly in the fuel supply system. In multiturbine installations, a difference measurement of the supply and return flow can provide individual turbine data. Claim Cost Reduction The planned down-time of a turbine is typically 5%. Unplanned shut downs can be very expensive, especially for IPP s, because a shut down can close an entire factory. For this reason, turbine manufacturers are seeing more penalty clauses that reduce the price or increase the warranty period. The reliable and leakagefree KRAL Volumeter prevents claims like these. A unique technical aspect is the sensor s dry sleeve, which keeps the flowmeter sealed if the sensor is taken out. When changing the sensor, there is no reason to open the meter, which would require depressurizing. Typical operating parameters for the KRAL fuel consumption measurement system Fuel: Turbine Diesel and marine fuel Flow rate: up to 2000 l/min Pipe size: up to 4", DN 100 Length: max. 500 mm (no flow conditioning required) Temperature: up to 150 C Consult factory for specific operating data or further information on the individual components of our fuel consumption measurement system. Compact Design Space is limited in power plant modules. Valves and pipe elbows are normally very close to a flowmeter. A flowmeter in a turbine module must be compact and not require additional room or flow conditioners. The Volumeter has a compact design compared with other high-pressure flowmeters. With a KRAL Volumeter there is never a need for flow conditioners. Robust Design p [bar] 200 100 10 20 symbolic diagram 30 t [ms] If dual fuel turbines switch over from natural gas to diesel oil, a valve is opened rapidly. This causes a strong pressure surge in the piping system. The flowmeter needs to have a robust design to handle such pressure pulses mechanically. KRAL Volumeters have a special spindle and casing design that protects the spindles from mechanical harm. 2
The Fuel Solution No flow conditioning or straight piping is necessary upstream or downstream of the meter. Through bolts for high-pressure safety. Rigid casing to handle pressure pulses without losing performance. Precision measuring chamber for high measurement accuracy. A second sensor can be installed for bi-directional flow measurement. Various connections are available for easy integration into existing piping, including: Pipe thread, ANSI, SAE, JIS and DIN flange. Sensor can be removed from dry sleeve even under full system pressure. 3
Water Injection Measurement for Turbines Stable measurement and easy installation for water injection measurement High flame temperatures create dangerous oxids fuel H C H H H H C H H H O2 air N2 + O2 N2 N2 O2 T>1200 C products CO2 NOX H2O NOX CO2 H2O NOX Reduction of Exhaust for Environmental Reasons Minimization of Water for Cost Reduction Typical operating parameters for the KRAL water injection measurement system Fuel: Demineralized water Flow rate: up to 700 l/min Pipe size: up to 2", DN 50 Length: max. 355 mm (no flow conditioning required) Temperature: up to 80 C Consult factory for operating data confirmation or further information for the individual components of our water consumption measurement system. Operating Principle Advantages Easy Installation Turbine improvement is a continuous task. Reduction of exhaust is a main target of these improvements. At temperatures above 1200 C the nitrogen of air burns into dangerous oxides (NOx). In order to reduce the NOx emissions, the temperature must be decreased. Water is injected to reduce temperature. The amount of water is controlled but not regulated. More and more turbine manufacturers want to regulate their water injection. For this kind of regulation, a suitable flow measurement is required. KRAL Volumeters are precise flowmeters that can measure water injection. Only demineralized water can be injected in the turbine. Demineralized water is very expensive. In some places it is more expensive than fuel. Because of this, water consumption should be optimized. Water consumption can be very high but it should not be any higher than necessary. A precise water measurement is required for optimization. The KRAL Volumeter is compatible with demineralized water and can measure this flow precisely. Every KRAL Volumeter is calibrated on the company s own test stand. This calibration is traceable to national standards. Electromagnetic and Vortex flowmeters are frequently used for water measurement. For this application, magnetic meters do not work with demineralized water since the liquid is non-conductive. Vortex meters need flow conditioning before the meter or they will not have the required accuracy. With the spindle design, KRAL Volumeters can function in water with high accuracy. No flow conditioners required 15xDN Other meters used for water measurement depend on the flow profile. They depend on flow conditioners which needs space for integration. If the flow conditioners is shortened to accommodate limited space, then it is not as effective. KRAL Volumeters do not depend on flow profile and need no flow conditioners for accurate measurement. 4
The Water Solution Flow profile does not affect meter accuracy. Precision measuring chamber provide accurate measurement of injection water. Flow Measurement at High Pressure High Accuracy Fast Response Stainless steel casing. Easy Installation Spindle design can The KRAL Volumeter measure demineralized OMH Series is designed water and requires for high no pressures, up to flow conditioning. 6000 psi. This is evident from the appearance of the meter: robust casing through bolts precise design exact machining With certain engineering changes, the OMH has been manufactured for line pressures up 15,000 psi. If you compare the meter photograph on the front cover and the cut-away photo above, you will notice the strong casing Various connections of the aremeter hides an unexpected integra-feature inside a available for easy tion into existing fine, piping, high-precision measuring instrument. including: Pipe thread, ANSI, SAE, JIS and DIN flange. Even with high system pressures, many applications also require high accuracy. The accuracy of a PD meter depends greatly on the geometry of the measuring chamber, which is formed by the spindles and casing. The OMH is designed to prevent any change in the measuring chamber, even under high pressure. The OMH also maintains high accuracy with: special spindle and casing design detailed machining calibration of each unit on our in-house test stand. Page 3 shows the design necessary for the high precision and turndown of the OMH. See the Rapid changes in flowrate and direction can often cause performance and mechanical problems for high pressure flowmeters. For applications such as a hydraulic test stand, a fast meter response is required for accurate and reliable measurement. The precise machining of the OMH allows the spindles to rotate easily without allowing liquid to pass through unmeasured. Even with flowrate and direction changes, the spindles can respond instantly and accurately. The fast response of the OMH is complimented by its wide flow and viscosity range, as shown in the Measuring Range diagram on page 6. There is often limited space available to install a flowmeter. As a solution, the OMH is compact and lightweight for this class of instrument. KRAL Volumeters are insensitive to flow disturbances, so there are no upstream or downstream installation requirements. The OMH can be installed at any angle. Even bi-directional flow can be measured precisely. Industry Standard connections and output signals allow for easy integration into new or existing Industry standard outputs systems. for easy integration. 5
KRAL Volumeter - Components of a Fuel Consumption and Water Injection Measurement System Application OMG* or OMH* OMS BEM 4U* BEM 2U* BGG EET Description Fuel consumption measurement Water injection measurement SFOC** measurement in [g/kwh] Sealed flowmeter for claim cost reduction Standard or High Stainless Steel Flow & Energy Local Dry Temp. Pressure Flowmeter Flowmeter Computer Display Sleeve Sensor or or or * For detailed product information, please request our product series brochures. ** Specific fuel oil consumption 6
Sound Applications to Choose KRAL Fuel Consumption Measurement on Turbines Water Injection Measurement on Turbines Diesel Engine FC Measurement Joint projects Liquid: Diesel Oil Flow rate: 28 to 1770 l/min Pressure: 142 bar Temperature: 15 to 80 C Viscosity: 1,6 to 6 mm 2 /s Measuring instrument: OMH 100 with -sensor A turbine manufacturer needed to measure the consumption of diesel oil in an explosion-proof area. The special requirements for this application included: high flowrate at high pressure in minimum space accurate and reliable measurements explosion-proof electronics long service life world-wide service The KRAL Volumeter OMH 100 was selected to measure the oil consumption of this turbine. Water injection principle water fuel Liquid: Demineralized Water Flow rate: 25 to 380 l/min Temperature: 5 to 40 C Pressure: 140 bar Measuring instrument: OMS 52 To reduce NOx exhaust our customer needed a turbine water injection regulation. For a regulation a turbine manufacturer required accurate measurement. He could not use magnetic or Vortex flowmeters because they don t work with demineralized water or need flow conditioners. The KRAL OMS 52 was selected, because this high accurate PD flowmeter measures demineralized water with high system pressure. There is never a need of flow conditioners. Liquid: Heavy Fuel Oil Flow rate: up to 170 l/min Temperature: 135 C Pressure: 8 bar Measuring instrument: OMG 52 KRAL is very experienced in fuel consumption (FC) measurement for Diesel engines. With multiple engine installations operators need an engine related measurement. This requires a measurement of the supply and return flow close to the injection pumps. The injection pumps cause pressure pulses which may be responsible for surge impact on the flowmeter. There are also fuel temperature differences. OMG with pressure-pulse and temperature compensation was selected. Our customers particularly value their co-operative collaboration with KRAL. Excellent business relationships arise again and again out of the best possible project implementation. We offer our customers inter-active dialogue and close technical co-operation to achieve a successful project conclusion. In partnership with KRAL, project goals are achieved. Please visit us at www.kral.at. 7
ender werbung Kräutler GmbH & Co., Bildgasse 40, A-6893 Lustenau, Austria, Telephone: +43 / (0) 55 77 / 8 66 44-0, Telefax: +43 / (0) 55 77 / 8 84 33 www.kral.at, E-mail: kral@kral.at Subject to change 12/01 All rights reserved.